exhaust

Muffler

for 2007 Ram 3500 5.9L I6 Cummins · 4WD

Difficulty

Easy

Time

54 min

Tools

Steps

✓Fact-checked. Built from OLP's spec database, then independently fact-checked line by line with every correction applied. Master-tech sign-off by Chris Hackleman is queued. Cross-check torque values against the factory manual, and stop if anything looks unsafe. How our data is made.

This procedure covers the removal and replacement of the muffler on a 2007 Ram 3500 with 5.9L Cummins diesel engine and 4WD.

Warnings

⚠️Ensure the exhaust system is completely cool before starting work. Exhaust components can retain heat for hours after engine shutdown and cause severe burns.

⚠Exhaust fasteners and clamps may be corroded. Apply penetrating oil and allow time to soak before attempting removal to prevent breaking studs or bolts.

⚠The muffler is heavy and awkward. Use proper lifting technique or have an assistant help support it during removal and installation.

Tools required

Floor jack and jack standsEssential

Torque wrenchEssential

15mm socket and ratchetEssential

18mm wrenchEssential

Penetrating oil

Wire brush

Safety glassesEssential

Work gloves

As an Amazon Associate and Autel/ANCEL partner, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.

Parts

Muffler assembly × 1 — Use OEM specification or equivalent aftermarket
Exhaust clamps × 2 — Use OEM specification
Muffler hanger insulators × 2 — Replace if worn or cracked

As an Amazon Associate and Autel/ANCEL partner, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.

Preparation

Park vehicle on level, solid ground and engage parking brake
Allow exhaust system to cool completely (minimum 2 hours after engine operation)
Raise vehicle using floor jack and support securely on jack stands at frame rails behind front wheels
Apply penetrating oil to all exhaust clamps and hanger bracket bolts, allow to soak for 15-20 minutes

Procedure

1
Locate muffler and support system
Position yourself under the vehicle and locate the muffler in the exhaust system between the intermediate pipe and tailpipe. Identify the inlet and outlet clamps and the two rubber hanger insulators supporting the muffler assembly.
2
Loosen inlet clamp
Using an 18mm wrench, loosen the clamp connecting the muffler inlet to the intermediate pipe. Do not fully remove yet. If the clamp is severely corroded, it may need to be cut off and replaced.
3
Loosen outlet clamp
Using an 18mm wrench, loosen the clamp connecting the muffler outlet to the tailpipe. Do not fully remove yet. This clamp is typically located just behind the muffler body.
4
Support the muffler
Place a floor jack or have an assistant support the weight of the muffler from below. The muffler weighs approximately 30-40 pounds and must be supported before releasing the hangers.
5
Remove rear hanger
Slide the rear rubber hanger insulator off the muffler mounting tab by pushing the muffler toward the front of the vehicle while pulling the insulator rearward. If the insulator is seized, carefully cut it off with a utility knife and replace with a new one.
Torque spec
Hanger Bracket Bolts25 Nm (18 lb-ft)
6
Remove front hanger
Slide the front rubber hanger insulator off the muffler mounting tab using the same technique as the rear hanger. The muffler should now be supported only by the jack or assistant.
7
Remove muffler
Fully remove both inlet and outlet clamps. Slide the muffler rearward to disconnect from the inlet pipe, then lower and remove from under the vehicle. Inspect all pipes for damage or excessive corrosion.
8
Clean pipe connections
Use a wire brush to clean the inlet and outlet pipe ends where the new muffler will connect. Remove all carbon buildup, rust, and old gasket material to ensure proper sealing with the new clamps.
9
Install new muffler
Position the new muffler under the vehicle and lift into approximate position. Slide the inlet over the intermediate pipe first, then align the outlet with the tailpipe. Leave connections loose for now.
10
Install hanger insulators
Install the front and rear rubber hanger insulators onto the muffler mounting tabs and corresponding frame brackets. Ensure insulators are fully seated and not twisted. New insulators may require lubricant (soapy water) to ease installation.
Torque spec
Hanger Bracket Bolts25 Nm (18 lb-ft)
11
Align exhaust system
Adjust the muffler position to ensure proper alignment with inlet and outlet pipes. Verify adequate clearance from the frame, driveshaft, fuel tank, and body components. There should be at least 1 inch clearance on all sides.
12
Tighten muffler clamps
Using a torque wrench and 18mm socket, tighten both the inlet and outlet clamps to specification. Tighten evenly to avoid cocking the clamp. Recheck alignment after tightening.
Torque spec
Muffler Clamps55 Nm (41 lb-ft)

Reassembly

Verify all clamps are torqued to specification and all hangers are properly seated
Check for adequate clearance around entire exhaust system with no contact points
Lower vehicle from jack stands

Verification

Start engine and listen for exhaust leaks at muffler connections (hissing or ticking sounds indicate leak)
With engine running, visually inspect muffler connections for exhaust gas escaping
Allow engine to reach operating temperature and verify no abnormal exhaust noise
Test drive vehicle and verify exhaust system does not contact frame or body components during acceleration or over bumps
After test drive, re-inspect all connections for leaks while engine is still warm

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